Hidden deck fastener

ABSTRACT

A hidden deck fastener or clip has a H-shaped body having a top portion having a thickness, a top surface and a bottom surface, and an integrally formed leg extending downwardly from the bottom surface, the leg defines channels in opposing sides thereof. A stepped fastener receiving opening is formed in the top portion and the leg. The opening has a first region formed into a part of the thickness of the top portion and a second region aligned and contiguous with the first region extending through the leg. The first region is a counterbore having a flat bottom. The fastener has a pull-out force resistance at least 50 percent greater than a comparable fastener having a countersink fastener receiving opening.

CROSS-REFERENCE TO RELATED APPLICATION DATA

This application claims the benefit of and priority to Provisional U.S.Patent Application Ser. No. 63/139,355 filed Jan. 20, 2021, titled,IMPROVED HIDDEN DECK FASTENER, the disclosure of which is incorporatedherein in its entirety.

BACKGROUND

The present disclosure relates to deck fasteners, and more particularlyto hidden deck fasteners having improved/greater pull out resistance.

Composite materials have become a mainstay of today's decking systems.These decking systems use fasteners to attach the decking to underlyingstructural members or joists. Fasteners can include screws, nails,staples or clips. Screws, nails and staples are typically installeddirectly through the top face of the structural members to the joistbelow.

Securing the decking members to the joists by direct fastening throughthe top face of the decking has many drawbacks. For example, thefasteners are visible, unattractive and take away from the facade orlook of the decking. Fasteners may corrode and discolor the deckingmembers. Fasteners may also become loose. In addition, in installingscrews, nails and staples hammer blows to the decking surface may causedamage and/or depressions in the decking.

Clips for securing the decking to the underlying joists are also known.In such a system, the decking members have longitudinal grooves orchannels formed along sides of the members.

Once such clip, referred to as a fastener, disclosed in Orchard, U.S.Pat. No. 9,181,715, and commonly assigned with the present application,includes a pi (II) shaped body having a top horizontal portion and apair of integrally formed spaced apart vertical legs that extenddownwardly from the horizontal portion. A space is defined between thelegs, and the legs are inwardly compressible (toward each other) inresponse to a side force. The top portion has raised ribs forfrictionally engaging the decking members. The clip has a bore throughthe top portion about mid-way along the length and width that alignswith the space between the legs. The bore has a countersink in the topsurface.

The clip is inserted into the grooves of adjacent decking members and issecured to the underlying joist by a countersink-headed fastener tosecure the fastener and the decking to the underlying joist. Such clipsare advantageous in that they are hidden—positioned between deckingmembers—and as such, fasteners are not installed in the surface of thedecking members.

While such clips function well, it has been found that a clip can pullout of the fastener. That is, the fastener remains in the underlyingjoist, but the clip pulls out, over the head of the fastener. As such,the clip no longer functions to secure the decking to the underlyingjoist.

Accordingly, there is a need for a clip to secure decking that is hiddenon installation. Desirably, such a clip has a high pull-out strength.Ore desirably still, such a clip grips the adjacent decking memberspreventing transverse movement, but allowing longitudinal movement forexpansion and contraction of the members.

SUMMARY

In one aspect an embodiment of a hidden deck fastener has a II-shapedbody having a top portion having a thickness, a top surface and a bottomsurface, and an integrally formed leg extending transversely, downwardlyfrom the bottom surface. The leg is spaced inwardly from sides of thetop portion and defines channels formed in opposing sides or edgesthereof. The channels can be formed having enlarged regions inwardly ofends thereof.

A stepped fastener receiving opening is formed in the top portion andthe leg. The opening has a first region formed into a least a part ofthe thickness of the top portion and a second region aligned andcontiguous with the first region extending through the leg. The firstregion is a counterbore having straight sides terminating at a flatbottom surface at the second region.

The channels in the legs extend toward and are spaced from the fastenerreceiving opening second region. The fastener has a pull-out forceresistance at least 50 percent greater than a comparable fastener havinga countersink fastener receiving opening.

In embodiments, the fastener further includes ridges formed on the topsurface and/or the bottom surface of the top portion. In a currentembodiment the ridges are formed on the bottom surface of the topportion.

In embodiments, the fastener receiving opening first region has adiameter about 2 times a diameter of the second region. The first regioncan be is formed in the top portion less than the thickness of the topportion.

In an aspect, the fastener includes a threaded fastener having a shankand a head. The head has a flat bottom surface to engage the flat bottomsurface of the fastener receiving opening first region.

In another aspect, in combination is a hidden deck fastener and athreaded fastener. The hidden deck fastener has a H-shaped body having atop portion having a thickness, a top surface and a bottom surface, andan integrally formed leg extending transversely, downwardly from thebottom surface.

The leg is spaced inwardly from sides of the top portion and defineschannels formed in opposing sides or edges thereof.

A stepped fastener receiving opening is formed in the top portion andthe leg. The stepped fastener opening has a first region formed into aleast a part of the thickness of the top portion and a second regionaligned and contiguous with the first region extending through the leg.The first region is a counterbore having straight sides terminating at aflat bottom surface at the second region.

The channels in the legs extend toward and are spaced from the fastenerreceiving opening second region.

The threaded fastener has a shank and a head. The head has a flat bottomsurface to engage the flat bottom surface of the fastener receivingopening first region.

The fastener has a pull-out force resistance at least 50 percent greaterthan a comparable fastener having a countersink fastener receivingopening.

In an embodiment, the fastener receiving opening first region has adiameter about 2 times a diameter of the second region. The first regionis formed in the top portion less than the thickness of the top portion.

In yet another aspect a decking and fastener system includes a deckingmember having an upper surface, a lower surface, and a side wallextending between the upper and lower surfaces. The side wall has agroove formed therein.

A hidden deck fastener has a H-shaped body having a top portion having athickness, a top surface and a bottom surface, and an integrally formedleg extending transversely, downwardly from the bottom surface. The legis spaced inwardly from sides of the top portion defining wings in thetop surface. The leg defines channels formed in opposing sides or edgesthereof.

A stepped fastener receiving opening is formed in the top portion andthe leg. The stepped fastener opening has a first region formed into aleast a part of the thickness of the top portion and a second regionaligned and contiguous with the first region extending through the leg.The first region is a counterbore having straight sides terminating at aflat bottom surface at the second region.

The channels in the legs extend toward and are spaced from the fastenerreceiving opening second region.

The hidden deck fastener is positioned adjacent the decking member witha wing positioned in the decking member groove and a threaded fastenerhaving a shank and a head having a flat bottom surface is driven intothe hidden deck fastener such that the flat bottom surface of the headengages the flat bottom surface of the fastener receiving opening firstregion.

The fastener has a pull-out force resistance at least 50 percent greaterthan a comparable fastener having a countersink fastener receivingopening.

In an embodiment, the fastener receiving opening first region has adiameter about 2 times a diameter of the second region. The first regionis formed in the top portion and can extend less than the thickness ofthe top portion.

In embodiments, the hidden deck fastener further includes ridges formedon the upper and/or lower surface of the top portion. In an embodiment,the ridges are formed on the lower surface.

Further understanding of the present disclosure can be obtained byreference to the following detailed description in conjunction with theassociated drawings, which are described briefly below.

DESCRIPTION OF THE DRAWINGS

An embodiment of a hidden deck fastener or clip is disclosed as anexample and is not limited by the figures of the accompanying drawings,in which like references may indicate similar elements and in which:

FIG. 1 is a top perspective view of an embodiment of a hidden deckfastener of the present disclosure;

FIG. 2 is a bottom perspective view of the fastener;

FIG. 3 is a top view of the fastener;

FIG. 4 is a bottom view of the fastener;

FIG. 5 is a side view of the fastener;

FIG. 6 is a sectional view of the fastener taken along line 6--6 of FIG.5;

FIG. 7 is an end view of the fastener installed between a pair of panelsand into a joist;

FIGS. 8A and 8B are force versus time curves from pull-out testing ofthe known clips (FIG. 8A) and the present clips (FIG. 8B);

FIGS. 9A and 9B are illustrations reproducing photographs of the knownclips (FIG. 9A) and the present clips (FIG. 9B) following pull-outtesting; and

FIG. 10 is an example of a fillister head wood screw for use with thefastener.

DETAILED DESCRIPTION

While the present disclosure is susceptible of embodiments in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred embodiment with the understanding that the presentdisclosure is to be considered an exemplification and is not intended tolimit the disclosure to the specific embodiment illustrated.

Referring now to FIGS. 1 and 2, there is shown a top perspective viewembodiment of an embodiment of a hidden deck fastener or clip 10(referred to herein as “clip”). The clip 10 has a pi (II) shaped body12, and includes a top portion 14 having wings 16 and a centrallylocated fastener receiving hole 18. In the illustrated embodiment thetop portion 14 is rectangular in shape in which the wings 16 areconfigured for insertion and retention in groove(s) 22 of deckingmember(s) 24. Cut-outs 26 are formed in the short sides 28 of the topportion 14 that are angular in shape. In an embodiment, the cut-26 outsextend through the top portion 14. It will be appreciated that the topportion 14 may be of any of a variety of suitable shapes, such as acircle, oval, biscuit or the like.

The fastener receiving hole 18 is located in the top portion 14, and inan embodiment, the receiving hole 18 is located in a longitudinal andtransverse center of the top portion 14.

A leg 30 extends downwardly and depends from a lower surface 32 of thetop portion 14. In an embodiment, the leg 30 is located in a transversecenter of the top portion 14, and the fastener receiving hole 18 extendsinto and through the leg 30. On either side of the hole 18, the leg 30include channels 34. The channels 34 extend inwardly from ends 36 of thelegs 30, toward by not into the fastener receiving hole 18, and formbifurcations 38 in each end 36 of the leg 30. A portion of each channel34 is enlarged as indicated at 40. The channels 34 extend up to aboutthe lower surface 32 of the top portion 14.

In embodiments, the lower surface 32 of the top portion 14 includes aseries of ribs or ridges 42 that extend downwardly from the lowersurface 32. The ridges 42 facilitate securing the clips 10 to thedecking members 24 as will be described below.

In a current embodiment, the fastener receiving hole 18 is a steppedhole having first or upper region 18 a and a second or lower region 18b. In an embodiment, the first region 18 a is formed into a portion ofthe top portion 14. That is, the first region 18 a is formed into aportion of the thickness of the top portion 14. The second region 18 bis aligned and contiguous with the first region 18 a and in anembodiment extends through a portion of the top portion 14 and throughthe leg 30.

As seen in FIGS. 1, 3 and 6, the first region 18 a has a cylindricalbore profile, or is a counterbore into a portion of the top portion 14.The second region 18 b is a continuation of a portion of the diameterd_(18a) of the first region 18 a (the counterbore).

The present deck fastener or clip 10 can be formed from a wide varietyof materials. Suitable materials include polymeric material such aspolypropylene and the like. Other suitable materials will be recognizedby those skilled in the art.

In an embodiment, the clip 10 has a top portion length l₁₄ of about 1.5inches, a width W₁₄ of about 0.75 inches and a depth or thickness t₁₄ ofabout 0.135 inches. The depth or thickness corresponds to the height h₂₂of the longitudinal grooves or channels 22 formed in the sides of thedecking members 24.

The ridges 42 on the top portion lower surface 32 extend from the lowersurface 32 about 0.025 inches. The leg 30 has a length l₁₃₀ of about 1.0inches, a height h₃₀ of about 0.39 inches and a width W₃₀ of about 0.163inches. The fastener receiving hole first region 18 a has a diameterd_(18a) of about 0.25 inches and a depth t_(18a) into the top portion 14of about 0.095 inches. The second region 18 b has a diameter d_(18b) ofabout 0.125 inches.

The clip 10 is secured in place using a fastener 46 having a head 48having a flat bottom 50, such as the illustrated filister head woodscrew (see, FIG. 10), a cap head, a hex washer head or the like.

In use, referring to FIG. 7, the clip 10 is positioned between twodecking members 24 with the top portion wings 16 positioned in the sidewall grooves 22 of adjacent members 24. It is anticipated that thebottom of the leg 30 will rest on a supporting structure, such as afloor joist 52. The ridges 42 on the lower surface 32 of the top portion14 will hold the clip 10 in place. The fastener 46 is positioned in thefastener receiving hole 18 and is driven into the structure or joist 52to fasten the clip 10 and decking member(s) 24 to the structure or joist52.

After installation the decking members 24 may expand and contract acrosstheir widths as a result of changes in the weather (temperature,humidity and precipitation) and as such, exert transverse or sidewayforces on the leg 30. The channels 34 allow for inward movement orcompression of portions of the leg 30 to accommodate expansion of themembers 24. As the decking members 24 contract, the leg 30 returns toits initial shape.

The decking members 24 may also expand and contract along their lengths.To prevent excessive longitudinal movement of the members 24, anembodiment of the clip 10 includes the ribs or ridges 42 that serve asfrictional elements to allow but limit longitudinal (lengthwise)movement of the decking members 24. While the ridges 42 are shown on thelower surface 32 of the clip 10, they can be on the lower or upper, orboth surfaces of the clip 10. These frictional elements can be ribs orridges 42 as shown, fingers, raised protrusions or like elements.

Tests were conducted to compare the pullout force required to pull clipsfrom their fasteners and the decking members. The tests compared thepresent clips to known clips such as those disclosed in theaforementioned patent to Orchard. Ten samples of each the present clipand the known clip were tested to determine the pull-out required topull the clip from a fastener.

The known clips were secured in a test rig using #7-10 1-⅝ trim headwood screws. The present clips were secured in the test rig using #7-101-⅝ fillister head wood screws. The tests were conducted at atemperature of 24° C. (75.2 ° F.). The pull-out force was measured inkilo-newtons (KN) and pounds-force (lbf). The results of the test areshown in Table 1 below.

TABLE 1 Comparison of Pull-Out Force for Known Clips and Present ClipsSample # Sample # (known Pull-out force (present Pull-out force clips,K#) (KN/lbf) clips, P#) (KN) K1 1.027 KN/230.87 lbf  P1 1.625 KN/365.3lbf  K2 1.047/235.37 P2 1.652/371.37 K3 0.987/221.88 P3 1.562/351.14 K41.107/248.9  P4 1.615/363.05 K5 0.856/192.43 P5 1.686/379.01 K61.007/226.37 P6 1.717/385.98 K7 1.029/231.32 P7 1.670/375.42 K81.010/227.05 P8 1.411/317.19 K9 1.072/240.99 P9 1.724/387.56 K101.035/232.67 P10 1.627/365.75 Max. 1.107/232.67 Max. 1.724/387.56 Min.0.856/192.43 Min. 1.411/317.19 Avg. 1.018/228.78 Avg. 1.629/366.18

As can be seen from Table 1, the resistance to pull-out of the presentclips (represented by the pull-out force required) is significantlygreater than the known clips. In every instance, the present clipsrequired a greater pull-out force (showed greater resistance topull-out) than the known clips. That is, the lowest pull-out force forthe present clips (1.411 KN) was greater than the greatest pull-outforce for the known clips (1.104 KN).

The average pull-out force required for the present clips (1.6291 KN)was 60 percent greater than the average pull-out force required for theknown clips (1.018 KN), calculated as ((1.629-1.018)/1.018), and thelowest pull-out force for the present clips (1.411 KN) was almost 34percent greater than the greatest pull-out force for the known clips(1.104 KN), calculated as ((1.411-1.104)/1.104).

FIGS. 8A and 8B are force vs. time curves generated during the testing,in which FIG. 8A is the curve for the known clips and FIG. 8B is thecurve for the present clips. As can be seen from the figures, there isan almost immediate failure (pull-out) of the known clips at about 5-10seconds whereas the present clips go well beyond 30 seconds, and over 36seconds before failure. Again, the curves also show that at about theaverage failure force of the known clips, all of the present clipsamples, were well within their functional range.

FIGS. 9A and 9B are illustrations reproducing photographs of the samplesfollowing testing in which FIG. 9A is an illustration reproducing aphotograph of the known clips and FIG. 9B is an illustration reproducinga photograph of the present clips. As can be seen from FIG. 9A, failureof the known clips was due to pull-out, whereas as seen in FIG. 9B,failure of the present clips 10 was not due to pull-out; rather, failureof the clips 10 was due to breakage of the clips themselves.

Accordingly, it will be appreciated that the present hidden deckfasteners 10 (again, referred to as clips) provide improved securementof decking members 24, are hidden on installation, and havesubstantially increased high pull-out strength compared to known deckingfasteners. The present clips 10 are easy to install and grip adjacentdecking member(s) 24 preventing transverse movement, but allow forlimited transverse and longitudinal movement for expansion andcontraction of the member(s) 24.

In the present disclosure, the words “a” or “an” are to be taken toinclude both the singular and the plural. Conversely, any reference toplural items shall, where appropriate, include the singular. All patentsand published applications referred to herein are incorporated byreference in their entirety, whether or not specifically done so withinthe text of this disclosure.

It will also be appreciated by those skilled in the art that anyrelative directional terms such as side(s), upper, lower, top, bottom,rearward, inboard, forward, outboard and the like may be for explanatorypurposes only and may not be intended to limit the scope of thedisclosure.

From the foregoing it will be observed that numerous modifications andvariations can be made without departing from the true spirit and scopeof the novel concepts of the present disclosure. It is to be understoodthat no limitation with respect to the specific embodiments illustratedis intended or should be inferred.

1. A hidden deck fastener, comprising: a II-shaped body having a topportion having a thickness, a top surface and a bottom surface, anintegrally formed leg extending transversely, downwardly from the bottomsurface, the leg spaced inwardly from sides of the top portion, the legdefining channels formed in opposing sides thereof, a stepped fastenerreceiving opening formed in the top portion and the leg, the steppedfastener opening having a first region formed into a least a part of thethickness of the top portion and a second region aligned and contiguouswith the first region extending through the leg, wherein the firstregion is a counterbore having straight sides terminating at a flatbottom surface at the second region, wherein the channels in the legsextend toward and are spaced from the fastener receiving opening secondregion, and wherein the fastener has a pull-out force resistance atleast 50 percent greater than a comparable fastener having a countersinkfastener receiving opening.
 2. The fastener of claim 1, furtherincluding ridges formed on the top surface and/or the bottom surface ofthe top portion.
 3. The fastener of claim 2, wherein the ridges areformed on the bottom surface of the top portion.
 4. The fastener ofclaim 1, wherein the fastener receiving opening first region has adiameter about 2 times a diameter of the second region.
 5. The fastenerof claim 1, wherein the first region is formed in the top portion lessthan the thickness of the top portion.
 6. The fastener of claim 1,wherein the channels have enlarged regions inwardly of an end thereof.7. The fastener of claim 1, further including a threaded fastener havinga shank and a head, wherein the head has a flat bottom surface to engagethe flat bottom surface of the fastener receiving opening first region.8. In combination: a hidden deck fastener and a threaded fastener, thehidden deck fastener having a II-shaped body having a top portion havinga thickness, a top surface and a bottom surface, an integrally formedleg extending transversely, downwardly from the bottom surface, the legspaced inwardly from sides of the top portion, the leg defining channelsformed in opposing sides thereof, a stepped fastener receiving openingformed in the top portion and the leg, the stepped fastener openinghaving a first region formed into a least a part of the thickness of thetop portion and a second region aligned and contiguous with the firstregion extending through the leg, the first region being a counterborehaving straight sides terminating at a flat bottom surface at the secondregion, wherein the channels in the legs extend toward and are spacedfrom the fastener receiving opening second region; and the threadedfastener having a shank and a head, wherein the head has a flat bottomsurface to engage the flat bottom surface of the fastener receivingopening first region, wherein the fastener has a pull-out forceresistance at least 50 percent greater than a comparable fastener havinga countersink fastener receiving opening.
 9. The combination of claim 8,wherein the fastener receiving opening first region has a diameter about2 times a diameter of the second region.
 10. The combination of claim 8,wherein the first region is formed in the top portion less than thethickness of the top portion.
 11. A decking and fastener system,comprising: a decking member having an upper surface, a lower surface,and a side wall extending between the upper and lower surfaces, the sidewall having a groove formed therein, a hidden deck fastener having aH-shaped body having a top portion having a thickness, a top surface anda bottom surface, an integrally formed leg extending transversely,downwardly from the bottom surface, the leg spaced inwardly from sidesof the top portion defining wings in the top surface, the leg definingchannels formed in opposing sides thereof, a stepped fastener receivingopening formed in the top portion and the leg, the stepped fasteneropening having a first region formed into a least a part of thethickness of the top portion and a second region aligned and contiguouswith the first region extending through the leg, the first region beinga counterbore having straight sides terminating at a flat bottom surfaceat the second region, wherein the channels in the legs extend toward andare spaced from the fastener receiving opening second region, whereinthe hidden deck fastener is positioned adjacent the decking member witha wing positioned in the decking member groove, and wherein a threadedfastener having a shank and a head having a flat bottom surface isdriven into the hidden deck fastener such that the flat bottom surfaceof the head engages the flat bottom surface of the fastener receivingopening first region, wherein the fastener has a pull-out forceresistance at least 50 percent greater than a comparable fastener havinga countersink fastener receiving opening.
 12. The system of claim 11,wherein the fastener receiving opening first region has a diameter about2 times a diameter of the second region.
 13. The system of claim 11,wherein the first region is formed in the top portion less than thethickness of the top portion.
 14. The system of claim 11, wherein thehidden deck fastener further includes ridges formed on the upper and/orlower surface of the top portion.
 15. The system of claim 14, whereinthe ridges are formed on the lower surface.